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Sona Skill Development Centre

Statistical Process Control


(25-26 July 2016)
Statistics
Statistics is a branch of mathematics that
deals with the collection, organization,
analysis and interpretation of data.
Statistical Process Control
The application of statistical techniques
to control a process by reducing variation
so that performance remains within
boundaries, or specification limits.
Statistical Quality Control
The application of statistical techniques
to control quality; includes acceptance
sampling (inspection of a sample from a
lot to decide whether to accept that lot).
Types of Data (Two Categories)
Attribute Data Variable Data
(Qualitative) (Quantitative)

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Population is a set of all items that possess a
certain characteristic of interest.
Sample is a subset of population, which is taken
from a population for certain purpose.
Parameter is a characteristic of population
something that describes it.
Statistic is a characteristic of sample. It is used to
make inferences on the population parameters
that are typically unknown.
Why Sample?
Census of a population (complete enumeration of
every item) may be:
 Impossible
 Impractical
 Too costly

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Simple Random Sample
Sampling from the population is often done
randomly, such that every possible sample will
have an equal chance of being selected.
A sample selected in this way is called a simple
random sample or just a random sample.

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Lessons Learned
Sample represents population.
There is an error.
Error can be reduced by increasing sample size.
Sampling method may affect results. (Random)
Distribution for a Targeted Process
Normal Curve and Probability Areas
PROCESS
• Requires understanding
• Has variation
• Has a capability
• Must be properly controlled
• Needs improvement
Distributions can differ in:

Or any combination of these


Rules About Output of a Process
• Customer needs determine the desired output.
• The process actually used determines the actual output.
• The actual process output inevitably has variance.
• Not inspection, but reduction in variation will result in
output that will satisfy customer’s requirements.
Variation: an opportunity for improvement
By fully identifying, characterizing, quantifying and
reducing variation, we can improve the bottom
line through reduced operating costs and improve
customer satisfaction through better service.
Process Variation is Natural and should be
expected from two types of causes.

Special Cause Variation


Upper Control Limit

Lower Control Limit

Common Cause Variation


Common Causes
Inherent in the process and affect every
occurrence of the process all the time.
Special Causes
Not in the process all the time and do not
affect every occurrence but arise because of
special circumstances (assignable)
Out of Control (Unstable Process)
Any process that operates with special causes,
is said to be out-of-control and process output
is not stable over time, therefore, not predictable.
Stable Pattern of Variation

Routine variation (due to what Dr. Deming called ‘common


causes’) is the variation inherent in the process—natural
variation imposed by the physical limits of the process

Routine variation is statistically the same as the process is


run from one time to the next or from one day to the next.
Unstable Pattern of Variation

Exceptional variation (due to what Dr. Deming called ‘special


causes’) typically results from not following the process
reliably i.e. each time the process is run, it is run differently.

This can happen because of poor employee training,


problems with equipment, poor process documentation,
unreliable supplier performance, or many other factors that
can change over time.
Making Matters Worse - Consequences
Characteristics Common Cause Special Cause
Nature System deficiency Process detail failure

Scope of influence All production output Not all production output


affected similarly affected similarly

Sources Many Small sources A few major sources

Process behaviour Stable and predictable Unstable and unpredictable

Approx % of total 85% to 95% 5% to 15%


variation

Improvement action Requires fundamental Requires point of production


change in design of process changes

Responsibility Management Operator / Supervisor


Control Charts
Understand

Analyze Display
A control chart is a line graph used to display variation on time
ordered fashion and separates special causes from common causes
of variation.
A centerline and control limits are placed on the graph to help
analyze the pattern of data. This is also called Process Behaviour
Chart. (W.A.Shewart 1924)
Abnormal situations in a control chart
The Three Core Variables
Control Charts
Individual X – Moving Range
Xbar – Range
Xbar - S
Individual X – Moving Range
Xbar – Range Chart
Xbar – s Chart
Comparison: Individual vs. Averages Charts
WHAT DO I DO NOW ?!!
Specification Limits
OK NG NG
Control Limits
OK
Specification Limits
OK NG NG
Control Limits
OK
umashankar.gautam@sonagroup.com
+91 9871194411

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